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  Fluorescent screen with metal back, and method of producing the sameUSPTO Application #: 20070034324Title: Fluorescent screen with metal back, and method of producing the same Abstract: A method for forming a metal back-attached phosphor screen comprises forming a phosphor layer on an inner surface of a face plate, transferring a metal film, and heating and pressing the metal film transferred onto the phosphor layer by a press roller. The transferring includes disposing a transfer film having at least a base film, a metal film and an adhesive-agent layer on the phosphor layer so that the metal film contacts the phosphor layer via an adhesive agent, heating and pressing by a transfer roller to let the metal film adhere thereto, and peeling the base film Both the temperatures of the pressing sections of the transfer roller and press roller are 150 to 240° C. and both the pressing rates are 1.0 to 6.0 meter/minute. A metal back-attached phosphor screen exhibiting an excellent adhesiveness between the phosphor layer and a metal back layer and a superior withstand voltage characteristic can be formed with a good process yield. (end of abstract) Agent: C. Irvin Mcclelland Oblon, Spivak, Mcclelland, Maier & Neustadt, P.C. - Alexandria, VA, US Inventors: Masayuki Yoshii, Takeo Ito, Hajime Tanaka, Yasinori Gamo, Masaki Inamura, Tomoko Nakazawa USPTO Applicaton #: 20070034324 - Class: 156233000 (USPTO) Related Patent Categories: Adhesive Bonding And Miscellaneous Chemical Manufacture, Methods, Surface Bonding And/or Assembly Therefor, Direct Contact Transfer Of Adhered Lamina From Carrier To Base, Metal Foil Lamina The Patent Description & Claims data below is from USPTO Patent Application 20070034324. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The present invention relates to a method for forming a metal back-attached phosphor screen, and particularly to a method for forming a metal back layer on a phosphor layer in a flat image display device such as a field emission display (FED) by a transfer method. BACKGROUND ART [0002] Conventionally, in an image display device such as a cathode-ray tube (CRT) or a FED, a metal back-attached phosphor screen in which a metal film such as of Al is formed on an inner surface (the face opposite to a face plate) of a phosphor layer is largely adopted. [0003] This metal back-attached phosphor screen aims to effectively transmit luminous energy to a front face of the face plate by reflecting a light emitted to the metal film (metal back layer) from the phosphor layer excited by electrons from an electron source, and to let the phosphor layer serve as an electrode by giving conductivity to the phosphor layer. [0004] The formation of the metal back layer is conventionally performed by methods such as a lacquer method in which a thin film made of nitrocellulose or the like is formed on the phosphor layer by a spin method or the like, Al is deposited thereon, and organic matters are removed by baking. [0005] Further, as a convenient formation method of the metal back layer, there is proposed a method (transfer method) in which a metal film is formed by a deposition on a film having a release agent previously coated thereon, and is transferred onto the phosphor layer with an adhesive agent. (Refer to Japanese Patent Laid-open Application No. Sho 63-102139.) [0006] However, in the conventional metal back layer formation method on the basis of the transfer, it is difficult to ensure enough adhesiveness between the phosphor layer and the metal back layer and realize a favorable withstand voltage characteristic. [0007] Specifically, in general, in the film transfer using a transfer roller,the thickness of a film to be transferred,the surface temperature of the transfer roller and the transfer rate are closely connected, and thereby the surface temperature of the transfer roller and the transfer rate are prescribed in accordance with the thickness of the transfer film and/or the softening temperature of the adhesive agent. In the metal back layer formation based on the transfer method, there is a problem that the setting ranges of the above-described respective conditions are small, and thereby a larger fluctuation is caused in the adhesiveness between the phosphor layer and the metal back layer, so that the withstand voltage characteristic fells to cause a transfer failure or a blistering failure, ending in a lower product yield. [0008] The present invention has been made to bring a solution to the above problem, and an object thereof is to provide a method for forming a metal back-attached phosphor screen exhibiting a favorable adhesiveness between a phosphor layer and a metal layer as well as a superior withstand voltage characteristic with a good process yield. DISCLOSURE OF THE INVENTION [0009] A method for forming a metal back-attached phosphor screen according to the present invention comprises forming a phosphor layer on an inner surface of a face plate, transferring a metal film, the transferring including disposing a transfer film having at least a base film, a metal film and an adhesive-agent layer formed on the base film so as to have the metal film come into contact with the phosphor layer through an adhesive-agent layer, heating and pressing by a transfer roller to adhere the transfer film onto the phosphor layer and then stripping the base film therefrom, and heating and pressing the metal film by a press roller, the metal film being transferred onto the phosphor layer, in which in the transferring, a temperature of a pressing section of the transfer roller is 150 to 240.degree. C. and a pressing rate thereof is 1.0 to 6.0 meter/minute, and in the heating and pressing, a temperature of a pressing section of the press roller is 150 to 240.degree. C. and a pressing rate thereof is 1.0 to 6.0 meter/minute. [0010] In this method for forming the metal back-attached phosphor screen, the thickness of the base film of the transfer film may be 5 to 30 .mu.m, the pressing force of the transfer roller may be 300 to 800 kgf/cm.sup.2, and the pressing force of the press roller may be 500 to 1000 kgf/cm.sup.2. [0011] Further, in the present invention, at least one of the transfer roller or the press roller may be the roller having a circumference of a length being equal to the length along a pressing direction of an area to be pressed in the transfer film or longer than it may be used. Moreover, both the transfer roller and press roller may have the circumference of the length being equal to the length along the pressing direction of the area to be pressed in the transfer film or longer than it. [0012] Furthermore, for at least one of the transfer roller or the press roller, a rubber roller having a covering layer of a thickness of 5 to 30 mm and made of a rubber having a hardness of 70 to 100 degrees on a metal core may be used. Moreover, both of the transfer roller and the press roller may be a rubber roller respectively having a covering layer of a thickness of 5 to 30 mm and made of a rubber having a hardness of 70 to 100 degrees on the metal core. BRIEF DESCRIPTION OF DRAWINGS [0013] FIGS. 1A and 1B are views schematically showing a transfer step by a transfer roller in the embodiment of the present invention, in which FIG. 1A is a plan view and FIG. 1B is a front view. [0014] FIG. 2 is a sectional view of a FED provided with a metal back-attached phosphor screen formed by the embodiment according to the present invention. BEST MODE FOR IMPLEMENTING THE INVENTION [0015] Hereinafter, embodiments of the present invention will be described. It should be noted that the present invention is not limited to the embodiments described below. [0016] In the embodiment according to the present invention, first, a light absorption layer (light-shielding layer) made of a black pigment and having, for example, a striped shape is formed on an inner surface of a face plate by a photolithography technology; a slurry containing phosphor materials of respective colors such as a ZnS group, a Y.sub.2O.sub.3 group, and a Y.sub.2O.sub.2S group is coated thereon and is dried; and a patterning is performed with the photolithography technology. In this way, a phosphor screen having striped phosphor layers of three colors of red(R), green (G) and blue (B) arranged side by side between the patterns of the light absorption layer is formed. The phosphor layers of respective colors can be formed by a spray method or by print processes. [0017] Subsequently, a metal film such as of Al is transferred onto the phosphor screen by a transfer method which will be described below. [0018] A transfer film has a multilayered structure in which a release agent layer, the metal film such as of Al and an adhesive agent layer are formed sequentially on a base film made of a polyester resin or so forth. Here, the film thickness of the base film is preferably 5 to 30 .mu.m so as to effectively perform heating and pressing by a transfer roller in a later-described transfer process. [0019] As a release agent, there are a cellulose acetate, wax, fatty acid, fatty-acid amide, fatty ester, rosin, acrylic resin, silicone, fluorocarbon resin and so forth, and out of these, some one is selected appropriately in accordance with the removability from the base film and a later-described protective film and so on to be used. Further, as an adhesive agent, a vinyl acetate resin, ethylene vinyl acetate copolymer, stylen acrylate resin, ethylene-vinyl acetate-acrylic acid terpolymer resin or the like is used. Furthermore, between the release agent and the metal film, a protective film composed of a thermosetting resin, a thermoplastic resin, a light-curing resin or the like as a base and containing a softening agent may be provided. Continue reading... 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